CRASH TEST REPORT FOR PERIMETER BARRIERS AND GATES TESTED TO SD-STD-02.01, REVISION A, MARCH 2003 Anti-Ram Bollards Prepared for: RSA Protective Technologies, LLC 1573 Mimosa Court Upland, CA 91784 Test Report No. KARCO Engineering, LLC AUTOMOTIVE RESEARCH CENTER 9270 Holly Road Adelanto, CA 92301 Tel: (760) 246-1672 Fax: (760) 246-8112 April 4, 2005
KARCO Engineering compiled this publication for information gathering only. The opinions, findings and conclusions expressed in this publication are those of the authors and not necessarily those of any other organization. KARCO Engineering provides test services only and is not involved in consulting, product design or the manufacturing of any automotive products. KARCO does not warrant, supervise or monitor compliance of products or services except as specifically agreed to in writing. By their very nature, testing, analysis and other KARCO services are limited in scope and subject to expected measurement variability. No activity by KARCO Engineering can release a manufacturer from product or any other liability. Tested By: Reviewed By: Approved By: Approval Date: Mr. Matthew A. Ivory, Project Manager Mr. Michael L. Dunlap, Quality Assurance Mr. Frank D. Richardson, Program Manager
TABLE OF CONTENTS Section Page 1 Introduction 1 2 Test Procedure and Instrumentation Summary 2 3 Test Results and Data Sheets 5 Table Page 1 Test Designations 2 Data Sheet Page 1 Test Vehicle Information 6 2 Test Vehicle Geometry 7 3 Evaluation of Test Results 8 4 Vehicle Accelerometer Data Summary 9 5 Camera Views and Film Speeds 10 Appendix Page A Photographs A B Data Plots B C Instrumentation List C D Manufacturers Drawings D i
LIST OF PHOTOGRAPHS Figure Page 1 Test Article as Received A-1 2 Right Front View at Test Article` A-1 3 Anti-Ram Bollard 5 inch Footing A-2 4 Bollard 10 inch Diameter and 1 inch Wall Thickness A-2 5 Bollard Foundation Module Front View and Re-bar A-3 6 Bollard Foundation Module Rear View A-3 7 Excavation A-4 8 Embedment Depth A-4 9 Test Article Positioned in Place A-5 10 Test Article During Installation A-5 11 Test Article During Installation A-6 12 Test Article During Installation A-6 13 Test Article Left Side View A-7 14 Test Article Left Front ¾ View A-7 15 Test Article Front View A-8 16 Test Set-Up A-8 17 Test Set-Up A-9 18 Test Set-Up A-9 19 Test Set-Up A-10 20 Test Set-Up A-10 21 Test Set-Up A-11 22 Test Set-Up A-11 23 Test Article Orientation to Front Bumper A-12 24 Test Article Orientation to Front Bumper A-12 25 Test Set-Up A-13 26 Ballast A-13 27 Post-Test Left Side View A-14 28 Post-Test Left Side view Close-Up A-14 29 Post-Test Front View A-15 30 Post-Test Overhead View A-15 31 Post-Test Test Article Front View A-16 32 Post-Test Test Article Left Side View A-16 33 Post-Test Test Article Left Side View A-17 34 Center Bollard Deflection A-17 35 Ballast A-18 36 Action Sequence 1 A-18 37 Action Sequence 2 A-19 38 Action Sequence 3 A-19 39 Action Sequence 4 A-20 ii
TABLE OF CONTENTS...(CONTINUED) LIST OF DATA PLOTS Plots Page B-1 Vehicle Rear Frame Rail X B-1 Vehicle Rear Frame Rail Y B-1 Vehicle Rear Frame Rail Z B-1 Vehicle Rear Frame Rail Resultant B-1 B-2 Vehicle Rear Frame Rail X Velocity B-2 Vehicle Rear Frame Rail X Displacement B-2 Table INSTRUMENTATION LIST Page C-1 Instrument Data Channel Assignments C-1 Figure MANUFACTURERS DRAWINGS Page 1 Manufacturers Test Article Layout Drawing D-1 iii
SECTION 1 INTRODUCTION 1.1 OBJECTIVES The primary objective of this crash test was to determine if the tested vehicle impact-rated barrier meets the minimum performance standards of the United States Department of State Specification for Vehicle Crash Testing of Perimeter Barriers and Gates (SD-STD-02.01, Revision A). This report presents the results of the performance and evaluation of one (1) full-scale crash test conducted on an RSA Anti-Ram Bollard system with 5 inch footings (ID=K8B5F5T). All tests were conducted in accordance with current SD-STD-02.01, Revision A, requirements for test designation K4. Procedures for receiving, inspecting, installation, testing and reporting of test results are described in the test procedure and are not repeated in this report. The purpose of this test was to evaluate the crash performance of the Anti-Ram Bollards. 1.2 TEST FACILITY All tests were conducted at KARCO Engineering s crash test facility in Adelanto, California. The tow road is constructed of reinforced concrete, presents a continuous level surface, and measures 850 feet in length. The width of the tow road is twelve feet with a thickness of six inches. A steel rail is embedded in the approach surface to provide vehicle guidance. Vehicle tow propulsion is provided by a 1 ton truck using a 2-to-1 pulley system coupled to a fixed prime mover (an internal combustion engine, Chevrolet V-8, 454 cubic inches displacement, with T-400 automatic transmission) and continuous cable drive system. The test vehicle is towed to within two feet of the barricade by a nylon rope clamped to a 3/8-inch steel cable. The clamp is released from the cable on contact with a cable release mechanism positioned to allow the test vehicle to proceed under its own momentum for the final two feet of travel before impacting the test array. 1.3 TEST ARTICLE Unit consists of 5, 40 inch high, 10 inch diameter Anti-Ram Bollards. The bollards have a 1 inch wall thickness and are filled with concrete during installation. Bollards are equally spaced at a distance of 4 foot 6 inches center to center. The system has a 5 inch footing that is installed 1.5 inches below the level concrete surface. 1
SECTION 2 TEST PROCEDURE AND INSTRUMENTATION SUMMARY 2.1 TEST PROCEDURE To meet the recommended properties of SD-STD-02.01-Rev A. impact requirements, a commercially available production model test vehicle was selected. This test was conducted using a 1987 International S1900, medium duty truck with conventional cab, front mounted diesel engine, rear wheel drive and an automatic transmission. The vehicle was in good condition, was free of major body damage, and was not missing any structural components. The bumpers were standard equipment and were not modified for this test. The materials, assembly instructions and physical configuration of the test article are specified in the manufacturer s documentation and are not repeated in this test report. Installation of the test article was conducted by the manufacturer. The test article, as installed at the test facility, is illustrated in Appendix A. 2.2 IMPACT CONDITIONS As recommended in SD-STD-02.01-Rev A test specification, the following full-scale crash test was conducted to evaluate the impact performance of the Anti-Ram Bollards. The primary intent of this test is to evaluate the ability of the bollards to arrest a 15,000 pound vehicle from penetrating or vaulting into a secured area and the extent, if any, of barrier deformation 2.2.1 Test Mass. The specific mass (gross weight) of the test vehicle as specified in the standard is 15,000 pounds (lb.) ±200 lb. The test weight, with instrumentation and ballast, was 15,142 lb. 2.2.2 Speed. Vehicle speed at impact with the test article shall be dependent on the condition designation as outline in Table 1. For this test designated as K4, the velocity at impact was 32.28 mph. Table 1. Test Designations IMPACT SPEED (mph) CONDITION DESIGNATION MINIMUM NOMINAL MAXIMUM K4 28.0 30.0 37.9 K8 38.0 40.0 46.9 K12 47.0 50.0 56.9 2
2.2.3 Approach Angle and Impact Point. The test vehicle is oriented such that it approaches the test article at a critical impact angle of ninety degrees (90 ±3º), relative to the roadway, with the centerline of the vehicle impacting the test article at the impact point designated by the DOS Technical Representative. The actual center of the impact point must be within ± 1 foot (ft.) of the target. The impact point designated for this test was the middle of the test article. The actual point of impact was perpendicular to and within 2 inches of the target. 2.3 TEST INSTRUMENTATION AND DATA ACQUISITION PROCEDURES All testing and data acquisition for this RSA Anti-Ram Bollard system with 5 inch footings (ID=K8B5F5T) certification test was performed in accordance with the SD-STD-02.01-Revision A test specification requirements. Appendix C contains a list of the instrumentation used in the performance of this test. 2.3.1 On-Board Data Acquisition. MDAS is an acronym for Miniature Data Acquisition System. The system is comprised of a 3-channel module. The module functions as a stand-alone, all-in-one unit with integral tri-axial accelerometer, computer control, signal conditioning, A/D circuitry, memory storage and battery pack. All functions are controlled by an off-board notebook or other PC compatible computer. Once the off-board computer initializes the system, it is designed to collect data with no off-board support. 2.3.2 Test Vehicle Instrumentation. Located near the vehicle rear frame rail, the test vehicle was instrumented with a tri-axial accelerometer to measure longitudinal (x), lateral (y) and vertical (z) acceleration. Data was recorded using the on-board MDAS three (3) channel module. Data was linked to a personal computer and processed using the MDAS crash test software. All equipment used in this test meets the requirements of SAE J211. 2.3.3 TDAS Software. The software utilized in this system is written in National Instruments LabWindows/CVI (C, Visual Interface) programming language, which is a Windows based (3.1 or Windows 95) software package with emphasis on ease of use and good engineering test practices. 2.3.4 SAE Compatibility. The software contains standard point and click processing options for selecting Society of Automotive Engineers (SAE) class post filters and calculating the required integrals, resultants, Head Injury Criteria (HIC), clips, and other data processing parameters that may be required. 3
2.3.5 Photographic Documentation. Photographic documentation of this test included three (3) realtime video cameras and (4) high-speed color digital video cameras at 1000 fps set up for an overhead view, a driver side view perpendicular to the point of impact a driver side view with a pre-determined angle to the point of impact and a frontal view. All high-speed cameras were activated by a pressure sensitive tape switch, which was positioned on the test article to indicate the instant of contact (time zero). A digital still camera was used for documenting the pre- and post-test condition of the test vehicles and Anti Ram Bollards. 2.3.6 Test Article Instrumentation. None 4
SECTION 3 TEST RESULTS AND DATA SHEETS 3.1 TEST DESIGNATION K8 This thirty miles per hour (32.28 mph) frontal impact crash test was conducted using a commercially available 1987 International S1900, medium duty truck to determine if the tested vehicle impact-rated bollards meet the minimum performance standards of SD-STD-02.01-Rev. A. The primary intent of this test was to evaluate the ability of the barrier to arrest a 15,000-pound vehicle from penetrating or vaulting into a secured area and the extent, if any, of bollard deformation. This was accomplished by measuring the vehicle penetration at the specified level of kinetic energy. The test article was positioned at an angle of ninety degrees (90 ) to the direction of travel of the impacting test vehicle, with the vehicle s centerline impacting the middle section of the bollard system. The vehicle was instrumented with a tri-axial accelerometer at the rear frame rail. This crash test was documented by three (3) real-time video cameras, and four (4) high-speed digital color cameras. Photographs of the test vehicle and the anti ram bollards are shown in Appendix A. 3.2 PRIMARY TEST RESULTS Test K4 was conducted on April 4, 2005. The test inertial weight of the vehicle was 15,142 lb. Test vehicle information is presented in Data Sheet No. 1 and Data Sheet No. 2. The test vehicle impacted the center of the barrier gate at a velocity of 32.28 mph. The evaluation of the anti ram bollard performance is presented in data Sheet No. 3. The vehicle was completely arrested by the barrier system. Pre- and Post-test photographs of the impact vehicle as well as of the bollards are shown Appendix A. Data plots of the event are presented in appendix B. The vehicle sustained severe damage to the entire cab. 5
DATA SHEET NO. 1 TEST VEHICLE INFORMATION Test Vehicle: 15,000 Ib. Truck Test No.: P25039-02 Test Program: RSA Bollards with 5 in. Footing Test Date: 4/4/05 Make Model Body Style VIN Color Odometer Reading Transmission Final Drive TEST VEHICLE INFORMATION International Cylinders S1900 Engine Displ. (L) Truck Engine Placement 1HTLOMJP4HH518679 Fuel Type White No. of Axles 170179 Disc Brakes, Front Manual Disc Brakes, Rear Rear Anti-lock Brakes 6 Unknown Longitudinal Diesel 2 No No No Manufactured By Date of Manufacture DATA FROM CERTIFICATION LABEL Navistar International Transportation Corp. May-87 GVWR (lbs) GAWR Front (lbs) GAWR Rear (lbs) Unknown Unknown Unknown DATA FROM TIRE PLACARD Measured Parameter Front Rear Max. Tire Pressure (psi) Unknown Unknown Cold Pressure (psi) Unknown Unknown Recommend Tire Size Unknown Unknown Actual Tire Size on Vehicle Unknown Unknown Actual Tire Manufacturer Unknown Unknown VEHICLE WEIGHTS As Received (lbs) As Tested (lbs) Front Rear Total Front Rear Total Left 3220 2550 5770 3666 4178 7844 Right 3272 2690 5962 3228 4070 7298 Totals 6492 5240 11732 6894 8248 15142 Ratio(%) 55% 45% 100% 46% 54% 100% 6
DATA SHEET NO. 2 TEST VEHICLE GEOMETRY Test Vehicle: 15,000 Ib. Truck Test No.: P25039-02 Test Program: RSA Bollards with 5 in. Footing Test Date: 4/4/05 TEST VEHICLE GEOMETRY (mm) A 780 D 3503 G 650 K 2250 B 500 E 2927 I 590 L 2050 C 800 F 1878 J 1050 N 1830 7
DATA SHEET NO. 3 EVALUATION OF TEST RESULTS Test Vehicle: 15,000 Ib. Truck Test No.: P25039-02 Test Program: RSA Bollards with 5 in. Footing Test Date: 4/4/05 CRASH TEST ASSESSMENT PASS FAIL Penetration of the Front Edge of the Cargo Bed Limited to One Meter Beyond the Pre-Impact, Inside Edge of the Barrier. Comments: Vehicle was completely arrested by the bollard system. x 8
DATA SHEET NO. 4 - VEHICLE ACCELEROMETER DATA SUMMARY Test Vehicle: 15,000 lb Truck Project No.: P25039-02 Test Program: RSA Bollards with 5 in. Footing Test Date: 4/4/05 VEHICLE ACCELEROMETER PEAK DATA Vehicle Location Axis Units Max Time Min Time Vehicle Rear Frame Rail X X G's 19.4 43.4-33.5 54.6 Vehicle Rear Frame Rail Y Y G's 37.1 65.4-35.3 73.2 Vehicle Rear Frame Rail Z Z G's 27.6 99.2-21.9 93.1 Vehicle Rear Frame Res. N/A G's 41.5 72.9 9
DATA SHEET NO. 5 CAMERA VIEWS & FILM SPEEDS Test Vehicle: 15,000 Ib. Truck Test No.: P25039-02 Test Program: RSA Bollards with 5 in. Footing Test Date: 4/4/05 No. Camera View Location (mm) X Y Z Angle (Deg.) Film Plane to Head Lens (mm) Speed (fps) 1 Real Time (Panning) 10288-20422 -2438-4 N/A N/A 30 2 Real Time (Driver's Side) -305-20422 -2438-4 N/A N/A 30 3 Real Time (Left Front 3/4 18288-3658 -914 0 N/A N/A 30 4 High Speed Digital Color (Driver's Side) 0-12802 -914 0 N/A 50 mm 1000 5 High Speed Digital Color (Overhead) -152 152-5791 -90 N/A 24 mm 1000 6 High Speed Digital Color -14935-14935 (Left Front 3/4) -1524-10 N/A 85 mm 1000 7 High Speed Digital Color -57912 (Front) 0-2438 -10 N/A 17-102 1000 All camera measurements were made relative to the point of impact. 10
APPENDIX A PHOTOGRAPHS A
FIGURE 1. Test Article as Received FIGURE 2. Right Front View at Test Article A-1
FIGURE 3. Anti-Ram Bollard 5 Inch Footing FIGURE 4. Bollard 10 Inch Diameter and 1 inch Wall Thickness A-2
FIGURE 5. Bollard Foundation Module Front View and Re-bar FIGURE 6. Bollard Foundation Module Rear View A-3
FIGURE 7. Excavation FIGURE 8. Embedment Depth A-4
FIGURE 9. Test Article Positioned in Place FIGURE 10. Test Article During Installation A-5
FIGURE 11. Test Article During Installation FIGURE 12. Test Article During Installation A-6
FIGURE 13. Test Article Left Side View FIGURE 14. Test Article Left Front ¾ View A-7
FIGURE 15. Test Article Front View FIGURE 16. Test Set-Up A-8
FIGURE 17. Test Set-Up FIGURE 18. Test Set-Up A-9
FIGURE 19. Test Set-Up FIGURE 20. Test Set-Up A-10
FIGURE 21. Test Set-Up FIGURE 22. Test Set-Up A-11
FIGURE 23. Test Article Orientation to Front Bumper FIGURE 24. Test Article Orientation to Front Bumper A-12
FIGURE 25. Test Set-Up FIGURE 26. Ballast A-13
FIGURE 27. Post-Test Left Side View FIGURE 28. Post-Test Left Side View Close-Up A-14
FIGURE 29. Post-Test Front View FIGURE 30. Post-Test Overhead View A-15
FIGURE 31. Post-Test Test Article Front View FIGURE 32. Post-Test Test Article Left Side View A-16
FIGURE 33. Post-Test Test Article Left Side View FIGURE 34. Center Bollard Deflection A-17
FIGURE 35. Ballast FIGURE 36. Action Sequence 1 A-18
FIGURE 37. Action Sequence 2 FIGURE 38. Action Sequence 3 A-19
FIGURE 39. Action Sequence 4 A-20
APPENDIX B DATA PLOTS B
Test Vehicle: 15,000 lb Truck Test Date: 4/4/05 Test Program: RSA Bollards with 5 in. Footing Project No.: P25039-02 20 10 G's 0-10 -20-30 -40-100 0 100 200 300 400 500 Time - Milliseconds Curve Description Vehicle Rear Frame Rail X CURNO Type SAE Class Units 001 FIL 60 G's Max Time Min Time 19.4 43.4-33.5 54.6 40 G's 20 0-20 -40-100 0 100 200 300 400 500 Time - Milliseconds Curve Description Vehicle Rear Frame Rail Y CURNO Type SAE Class Units 002 FIL 60 G's Max Time Min Time 37.1 65.4-35.3 73.2 G's 30 20 10 0-10 -20-30 -100 0 100 200 300 400 500 Time - Milliseconds Curve Description Vehicle Rear Frame Rail Z CURNO Type SAE Class Units 003 FIL 60 G's Max Time Min Time 27.6 99.2-21.9 93.1 G's 50 40 30 20 10 0-10 -100 0 100 200 300 400 500 Time - Milliseconds Curve Description Vehicle Rear Frame Rail Resultant CURNO Type SAE Class Units 001 RES 60 G's Max Time Min Time 41.5 72.9 0.2 459.1 B-1
Test Vehicle: 15,000 lb Truck Test Date: 4/4/05 Test Program: RSA Bollards with 5 in. Footing Project No.: P25039-02 40 MPH 30 20 10 0-10 -100 0 100 200 300 400 500 Time - Milliseconds Curve Description Vehicle Rear Frame Rail X Velocity CURNO Type SAE Class Units 001 IN1 180 MPH Max Time Min Time 32.3 2.5-1.4 438.8 75 Inches 50 25 0-25 -50-100 0 100 200 300 400 500 Time - Milliseconds Curve Description Vehicle Rear Frame Rail X Displacement CURNO Type SAE Class Units 001 IN2 180 Inches Max Time Min Time 61.5 245.6 0.0 0.0 B-2
APPENDIX C INSTRUMENTATION LIST C
RSA Bollards with 5 in. Footing Instrumentation Data Channel Assignments 4/4/05 15,000 lb Truck CH. LOCATION AXIS IDENT. NO. DESCRIPTION MFR MODEL UNITS 1 Rear Frame Rail X MDASX Accel., Vehicle block I.C.Sensor 3031-100 G 2 Rear Frame Rail Y MDASY Accel., Vehicle block I.C. Sensor 3031-100 G 3 Rear Frame Rail Z MDASZ Accel., Vehicle block I.C. Sensor 3031-100 G C-1
APPENDIX D MANUFACTURERS DRAWINGS D